SNECMA. Health Monitoring Algorithms. Expert Emérite Safran SNECMA

Transcription

1 SNECMA Health Monitoring Algorithms Expert Emérite Safran SNECMA

2 A SAFRAN Company 1 / SNECMA / R&T / INTEGRATION / ALGORITHMS

3 (1) PowerJet (50-50 Snecma/NPO Saturn) (2) CFM International (50-50 Snecma/GE) (3) EPI (ITP, MTU, Rolls-Royce, Snecma) (4) In cooperation with GE Satellites PPS mn Ariane 5 HM7B 64.8 kn Ariane 5 Vinci 180kN Ariane 5 Vulcain kn (main stage) Alpha Jet Larzac 14kN Mirage F1 Atar 49kN Rafale M88 75kN Mirage 2000 M53 95kN A400M TP400 (3) hp Citation Longitude Silvercrest 9,500 to 12,000 lb SSJ100 SaM146 (1) 13,500 to 17,800 lb 737 CFM56-7B (2) 19,500 to 27,300 lb A320 CFM56-5B (2) 21,600 to 33,000 lb A320neo LEAP-1A (2) 21,500 to 33,000 lb 737 MAX LEAP-1B (2) 21,500 to 28,000 lb C919 LEAP-1C (2) 21,500 to 30,000 lb A340 CFM56-5C (2) 31,200 to 34,000 lb 747 CF6 (4) 52,500 to 72,000 lb A380 GP7200 (4) 70,000 to 85,100 lb 777 GE90 (4) 93,700 to 115,300 lb 2 / SNECMA / R&T / INTEGRATION / ALGORITHMS

4 Design, development, production, sale and support of commercial aircraft engines in the 18,000 to 50,000 lb thrust range Fan Accessory gearbox Low-pressure turbine Core engine Sales zones CFM is an equally-owned subsidiary of Snecma (Safran), France and GE, United States. 3 / SNECMA / R&T / INTEGRATION / ALGORITHMS

5 CFM56-5B Over 95 million flight-hours to date* 5,500* engines in service with 130 operators Thrust range: 21,600 to 32,000 lb Applications: Airbus A318, A319, A320, A321 A320 * As of December 31, 2012 CFM56-7B More than 176 million flight-hours to date* 9,180* engines in service with 190 operators Thrust range: 19,500 to 27,300 lb Applications: Boeing , , , Boeing * As of December 31, 2012 CFM is an equally-owned subsidiary of Snecma (Safran group, France) and GE (United States). 4 / SNECMA / R&T / INTEGRATION / ALGORITHMS

6 Featuring innovative technologies that have been proven effective (new materials, 3D aero, etc.), the LEAP engine combines performance, reliability, environmental-friendliness and reduced operating costs. Fuel consumption and CO 2 emissions: 15% lower than CFM56 TI engines NOx: 50% margin versus the CAEP/6 standard Noise: Compliant with anticipated Chapter 5 regulations Same reliability as CFM56 with equivalent maintenance costs Thrust range: 20,000 to 33,000 lb More than 4,350 orders and commitments as of December 2012 Selected to power the Airbus A320neo, Boeing 737 MAX and Comac C919 Airbus A320neo Boeing 737 MAX Comac C919 Service entry in 2016 CFM is an equally-owned subsidiary of Snecma (Safran group, France) and GE (United States). 5 / SNECMA / R&T / INTEGRATION / ALGORITHMS

7 SaM146 engine design, production, sale and support Core engine Accessory gearbox Control system Snecma is responsible for propulsion system integration and flight tests Fan Low-pressure compressor Low-pressure turbine NPO Saturn is responsible for final engine assembly and ground tests PowerJet is an equally-owned subsidiary of Snecma (Safran), France and NPO Saturn, Russia SSJ SSJ SaM146 1S18 EASA certification: January 17th, 2012 Thrust range: 16,100 to 17,800 lb Applications: SSJ100-95LR, SBJ (EASA certified on February 3th, 2012) 6 / SNECMA / R&T / INTEGRATION / ALGORITHMS

8 Designed to power super mid-size and large business jets Innovative solutions to simplify engine architecture and reduce the parts count, for significant benefits: Specific fuel consumption 15% lower than current engines 50% reduction in NOx (nitrogen oxides) in compliance with CAEP/6 Noise: Up to 20 EPNdb margin vs. Stage 4 requirements Thrust range: 9,500 to 12,000 lb Super midsize business jets Large business jets Long-range business jets Selected to power the Cessna Citation Longitude Service entry in / SNECMA / R&T / INTEGRATION / ALGORITHMS

9 M88 Over 310 engines in service Over 230,000 flight-hours Thrust: 75 kn Applications: Dassault Rafale air force (C/B) and naval (M) versions Rafale * As of December M53 Over 580 engines produced for 9 air forces Nearly 1.8 million flight-hours Thrust: 95 kn Applications: Dassault Mirage 2000 C/B, Mirage 2000 N/B Mirage /-9 Mirage 2000 N/B * As of December / SNECMA / R&T / INTEGRATION / ALGORITHMS

10 Europrop International European consortium grouping ITP (Spain), MTU Aero Engines (Germany), Rolls-Royce (UK) and Snecma Safran (France). Europrop International is responsible for engine integration and program management Combustor High-pressure turbine Accessory gearbox Workshare: 32% Intermediate casing High-pressure compressor Inter-turbine casing Workshare: 25% Intermediate-pressure turbine Intermediate-pressure compressor Workshare: 22% Inlet casing Low-pressure turbine Exhaust casing Workshare: 21% A400M 9 / SNECMA / R&T / INTEGRATION / ALGORITHMS

11 Over 60 years of experience in liquid rocket propulsion, including 30 years on the Ariane 1 to 5 launchers HM7B Thrust: 14,300 lb (64.8 kn) More than 1,200 engines launched. European cryogenic propulsion prime contractor: Vulcain 2 and HM7B for Ariane 5, the world s leading commercial launch vehicle. Prime contractor for development of the propulsion system on a new restartable upper stage for Ariane 5, powered by the new Vinci engine. Vinci (restartable) Thrust: 39,600 lb (180 kn) (Under development) Vulcain 2 Thrust: 297,000 lb (1,340 kn) Ariane 5 ECA 10 / SNECMA / R&T / INTEGRATION / ALGORITHMS

12 3 Support services spanning the entire life cycle Engine life operating support In-shop engine maintenance 8 engine overhaul centers Component repair 12 parts repair centers of excellence Global MRO market positions CFM56 No. 2 worldwide for shop visits GE90 No. 1 worldwide for high-pressure and low-pressure compressors GP7200 No. 1 shop to provide HPC servicing More than 24,000 engines & subassemblies repaired to date 11 / SNECMA / R&T / INTEGRATION / ALGORITHMS

13 Prognostic & Health Monitoring 12 / SNECMA / R&T / INTEGRATION / ALGORITHMS

14 Engine APU Actuators Cables Gears, Brakes 13 / SNECMA / R&T / INTEGRATION / ALGORITHMS

15 HP shaft 2 bearings (15000 to rpm) Around 20 disks with 20 to 80 blades each LP shaft 3 bearings (5000 to 8000 rpm) Oil and Fuel systems Equipments assembled on an Accessory Gear Box (AGB). Sensors: accelerometers, tachometers, pressures, temperatures, flows 14 / SNECMA / R&T / INTEGRATION / ALGORITHMS

16 On board Monitoring function located in the engine control system Data transfer using aircraft system (ACMS) Fadec system Avionics Transfer to the ground 3 possibilities (depending on the application) During the flight (ACARS or SATCOM) End of the flight (GSM or WiFi or manual) Scheduled time Remote Diagnostics On ground Ground Monitoring System (GMS) with Web portal Client Support Center (CSC) Maintenance 15 / SNECMA / R&T / INTEGRATION / ALGORITHMS

17 16 / SNECMA / R&T / INTEGRATION / ALGORITHMS

18 Methodology and Algorithms 17 / SNECMA / R&T / INTEGRATION / ALGORITHMS

19 service ACARS Message ACARS Message ACARS Message ACARS Message ACARS Message Alert database server company First level SPC Second level Trends Third level Diagnostics Forth level Web service Trend analysis provides a second level of monitoring specific for each engine Statistic Process Control is a first layer of alert system based on security thresholds ACARS messages are snapshots send to the ground from airplanes. Fleet analysis with relation to maintenance operation is an help for service Maintenance operators exploit analysis to improve and accelerate operations. A web service enable company users to get observation and services results 18 / SNECMA / R&T / INTEGRATION / ALGORITHMS

20 service ACARS Message ACARS Message ACARS Message ACARS Message ACARS Message Alert database server company First level SPC Second level Trends Third level Diagnostics Forth level Web service Embedded computation compression Dev. DB Source control algos Test database Engine test benches TMM server TMM client synchronization Configuration database Maintenance database 19 / SNECMA / R&T / INTEGRATION / ALGORITHMS

21 Once endogenous and exogenous sets of inputs defined The diagnostic is the computation of a likelihood according to a conditional data model The quality of the model depends on the calibration dataset A robustness (capacity of generalization) may be computed by cross validation Input Normalizes engine data according to flight context Models inputs, and computes regression residuals Model residual distribution, classify signatures faults Endogenous engine/bench data Normalize Model Score Indicators Exogenous context data Robustness Risk Reliability 20 / SNECMA / R&T / INTEGRATION / ALGORITHMS

22 The prognostic is the result of A detection High risk and good quality A confirmation of the detection Successive detections An anticipation By estimation of the increasing rate of scores The confirmation methodology helps adjust PFA (false alarm rate) and POD (probability of detection) performance indicators according to the specs. Diagnostic signatures A detection is the crossing of risk and quality thresholds Uses successive observations to validate a detection Estimates a potential trend and computes the probability to cross a threshold in the future Risk Fault identification Confirmation Trends computation Reliability Messages 21 / SNECMA / R&T / INTEGRATION / ALGORITHMS

23 Each diagnostic algorithm produces three outputs The risk Is the probability to be unusual The precision The variance of the risk (reliability information) The adequacy Inputs Context The probability that the computation is done in a context that corresponds to the calibration dataset The robustness Is the generalization error computed by cross-validation Robustness Learning Model Precision Risk Adequacy Reliability U is the exogenous data X is the endogenous data (u t, x t ) is the current observation 22 / SNECMA / R&T / INTEGRATION / ALGORITHMS

24 Identification & selection of important parameters Vibration (HF) analysis, features extraction Variable selection, mutual information, Learning of normal behavior Likelihood scores, extreme values, statistic tests Abnormality signature classification Auto-organizing maps, outliers detection Auto adaptive classification Trends detection and failure anticipation Regressions, filters (*KF), importance sampling (PF) Reliability management and diagnosis fusion Bayesian models, statistics, logical inference (Fuzzy) 23 / SNECMA / R&T / INTEGRATION / ALGORITHMS

25 diagnostic of a damaged bearing Raw data acquisition and temporary storage of vibrations 3 on-board vib analysis conditioning Sensors : 2 accelerometers (vibrations) tachometers (rotating speeds) vib transfer across structures Automatic decision classification per component/ failure mode/ Fault : 1 damaged bearing B1 B2 B3r B3b B4 B5 sensor/ regime fusion decision 6 flight Multi-domain signal processing: time frequency Side-band order envelope 4 Orders BPFO time features extraction Features extraction for specific damages features based on models features per component 5 component time 24 / SNECMA / R&T / INTEGRATION / ALGORITHMS

26 Supervision console SPC system PHM system online store redo Test cell Cell Database Context selection Context class identification Alert Alert Data acquisition Curve compression into indicators Parameters selection Local Diagnostic Prognostic 25 / SNECMA / R&T / INTEGRATION / ALGORITHMS

27 Using a fleet of engines and a historic database, the state of each engine is compressed in a 2D space that conserve distance order. Each engine trajectory may be drawn on the map. Trajectories comparisons allow the computation of statistics. Engine to analyze Edit distance between trajectories on the map Small subset of engines that show similar behavior in the past Statistics Past events 26 / SNECMA / R&T / INTEGRATION / ALGORITHMS

28 The VSV (Variable Stator Vanes) is operated by two mechanically linked actuators two LVDT (Linear Variable Differential Transformer) position sensors a servovalve that transforms the electronic command into hydraulic power by means of fuel flow N1, N2, PS3, WFM Engine Engine environment Position order PID regulator u Hydraulic actuator Stator Command Real Position FADEC Harness y LVDT Sensor Position HM Algorithm The algorithm analyzes the behavior of the control loop The normal behavior is modeled on ground, producing a reference The algorithm automatically compute a local model on line Then it compares the new behavior to the reference 27 / SNECMA / R&T / INTEGRATION / ALGORITHMS

29 Thank you 28 / SNECMA / R&T / INTEGRATION / ALGORITHMS